1. Die Casting Fluid Flow Simulation
22nd International Die Casting Congress & Exposition
０／１３
SEPTEMBER 15-18, 2003 • INDIANAPOLIS, IN
More Accurate
Die Casting Fluid Flow Simulation
by Direct Observation
of Die Cavity Filling
Hidenori IIMI, Yukiko NGANAWA
DENSO CORPORATION
Yoshiro KAMEYAMA
　　　　　　　DENSO TECHNO CORPORATION
Eiji KATO, Hiroyuki NOMURA
　NAGOYA University

2. By Direct Observation Cavity Filling Inside of Die
1. BACKGROUND
１／１３
Die Casting fluid flow simulation
Virtual Die Casting Trial on Computer ⇒Predict Process in the Die
（Filling Pattern,…,Defects）
→ Design improving
Heat Transfer
Filling
Die Cavity
Solidification
Metal Flow & Solidification Simulation
Reduce Try ＆ Error⇒Several Tens Million yen/year Cost Down
Accuracy of Simulation？
But…
Until Now：Confirm by Product Quality (defects,…)
→ Inside of Die Process is Difficult to Confirm
→We doubt about Accuracy(Especially Filling Pattern)
Need to Confirm Accuracy
By Direct Observation Cavity Filling Inside of Die

3. 2. CONTENTS ２／１３ 1) Direct Observation of Molten Metal Filling Pattern
inside Die casting Die (Method,Result)
2) Accuracy Inspection of
Die casting Filling Simulation
(Method,Result)
3) Consideration of Reason why
Low Accuracy
4) Improving the filling simulation
(Method,Result)
5) Conclusion

4. Observation of Filling Pattern of each Product Cavity
３／１３
3. EXPERIMENT METHOD (1)GATE SYSTEM
(unit: mm) 23
Overflow 23 15
(ｔ=8)
Product part
Air Vent
　(t=0.2)
(3cavities)
(ｔ=6)
(ｔ=1)
115 60
Hole
　φ6
Gate 15
(ｔ=8) 10
(ｔ=12) 60
Runner
(ｔ=0.8) 12
(ｔ=5)
φ35
Sleeve
Shot
Plunger
（Fan Gate shape）
Shot Weight：160g (Aluminum)
Size: 122x70mm (about A5 size )
Gate System(Simple Shape for easy Inspection )
Observation of Filling Pattern of each Product Cavity

5. 4. EXPERIMENT METHOD (2)MACHINE
４／１３
4. EXPERIMENT METHOD (2)MACHINE
Heat-Resistant Glass
Window
Acrylic Resin Board
Die
High Speed
Video Camera
(KODAC ECTAPRO V4540)
Electric Die Heater
Electronic Servo Cylinder
Direct
Observation
Shot Plunger
Molten Metal
Sleeve
Die Casting Machine for Direct Observation
Direct Obsevation Filling Behavior Through the Window

6. Appearance of the Die Casting Machine Electronic Servo Plunger
Appendix
Appearance of the Die Casting Machine
Light
Electronic Servo Plunger
Window for Observation
High Speed
Video Camera※
Light Brightness (Voltage)Control
Electric Die Heater
Fixed Die
※Actual Used
Camera
Moving Die
KODAC ECTAPRO
V4540

7. Inside of the Die Appendix Moving Die(Frame) Heat-Resistant Glass
Acrylic Resin
Die(Product Cavity)

8. Very Short Time Phenomena
５/１３
5. EXPERIMENT METHOD
(3)Experiment Condition
・Casting Material：JIS-ADC１２ （A383）
　　　　　　　(Al-11%Si-2.6%Cu-0.6%Fe-0.01%Mn･Mg･Ni･Zn)
・Shot Weight:160g
・Casting Temp.：690℃ (in ladle)
・Plunger Speed：0.1，0.2，0.3m/s (ｎ＝３ each）
(Max Pressure:７５０ kgｆ/cm2)
・Die Temp.:190℃ （holding by electric heater）
・Movie Record Speed：250 frame/s
Very Short Time Phenomena
(within 0.05～0.2s )

9. ６／１３
6. RESULT OF EXPELIMENT
Shot Speed　0.1m/s

10. 7. SIMULATION METHOD ７／１３ ●Software：ProCAST ●FEM Model for Simulation：
　　　　　　　　　 ［FEM-Metal Casting ］
●FEM Model for Simulation：
・number of Mesh 36,028，
・number of Nodes 43,798　
●Boundary Condition,etc.：
・Wall condition(Flow) NonSlip
・Heat Transfer Coefficient
（Die-Casting） 8,400 W/ m2･K
（Glass-Casting）0 W/ m2･K Insulate condition
・Material Data　JIS-ADC12 （A383）
(default data of software db)
・Inlet Speed/InitialTemp:same to Exp.
Inlet
FEM Model

11. ８／１３ （Shot Speed 0.1m/s） Quite Different １.０ ０.５ ０.０
8. RESULT OF SIMULATION
８／１３
（Shot Speed 0.1m/s）
EXPERIMENT
STOP at Central Gate
0.068
0.092
0.104
0.132
0.172
0.200sec
SIMULATION
Low Accuracy…
Quite Different
Flow into Central GATE
Stop for a while
０.０
１.０
０.５
0.070
0.090
0.100
0.130
0.170
0.200sec
Solidification Rate

12. STOP AT ONCE at Central Gate
9. CONSIDERATION OF EXPERIMENT
９／１３
STOP AT ONCE at Central Gate
and Flow to Side
Shot Speed 0.1m/s
STOP at Central Gate
0.2m/s
0.3m/s
Effect by Solidification ⇒Solidification Factor in Simulation?

13. Use data from many reference paper
１０／１３
10. Solidification Factor in SIMULATION
1. Temperaure
heat transfer coefficient：　ｈ
heat conductivity：　λ
Use data from many reference paper
2. Flow-Solidification Equation
Navieｒ-Stoke's Eq.＋Cozeny-Carmen Eq.
Viscosity
Flow
Filter coefficient
solid
Liquid
Solidification Rate Increace⇒Flow Resistant Increace
Soidification Rate
3. Material Property Data
(Temp.-Solid Rate Data)
JIS-ADC12 (A383):
（Al-11%Si-2.6%Cu-0.6%Fe-0.01%Mg・Zn・Ni）
1.0
Al-Si eutictic alloy
Until Now：Linear Approximation Data
Solid Rate
Poor
Expect（multiple alloy）
Need to Improve Material Data
More Accurately
Until Now
515
580
Temp(℃)
Solidus
Liquidus
Investigation How to get Material Data

14. 11. IMPROVE THE MATERIAL PROPERTY DATA
１１／１３
11. IMPROVE THE MATERIAL PROPERTY DATA
Poor Data ; Temp.–Solid Rate Curb Data
→Improve(Calculate data by Thermo-Calc(※))
（※）Thermo-dynamic calculation software
Calculated
Solid Rate
Until Now
Temperature(℃)
Improving Data ［Temp.-Solidification Rate(JIS-ADC12)］
Simulation Again with the Improved Material Data

15. Simulation correspond to the Experiment High-Accurately
１２／１３
12. CONFIRM OF IMPROVE DATA EFFECT
STOP at Central Gate
Solid Rate
０.０
１.０
０.５
0.068
0.092
0.104
0.132
0.172
0.200
Simulation correspond to the Experiment High-Accurately

16. 13. CONCLUSION １３／１３ (1)Realized Experiment ; Direct Observation
Metal Filling Behavior inside of multiple die
Cavity.
(2)Die Cavity Filling Simulation of Experiment (1),
and Confirm the Simulation until now can’t
Reproduction Flow Stop by Solidification
Progress.
(3)Improve Cast Material Property Data for
Simulation, As a result, Confirm Simulation
high-accurately Correspond to the Experiment

17. Appendix
RESULT OF EXPELIMENT
Shot Speed　 0.2m/s

18. Appendix
RESULT OF EXPELIMENT
Shot Speed　 0.3m/s